Horizontal ultrasonic broaching machine and high-efficiency broaching parameter design method

Abstract

The application discloses a horizontal ultrasonic broaching machine tool and an efficient broaching parameter design method. A stepping motor is fixedly arranged in a base in the horizontal ultrasonic broaching machine tool. A C-shaped cradle is arranged in the base, a rack of the C-shaped cradle is in sliding connection with a gear of the stepping motor in the base, and the rack of the C-shaped cradle is driven to rotate by the gear of the stepping motor. A workbench is installed on the C-shaped cradle, the workbench is connected with the C-shaped cradle through a first screw rod, and the workbench is driven to move horizontally on the C-shaped cradle by the stepping motor. A turbine disc is fixedly arranged on a rotary table, the turbine disc is used for fixing an internal gear workpiece, the rotary table is installed on the workbench and is driven to rotate on the workbench by the stepping motor, and the turbine disc rotates with the rotary table. An ultrasonic auxiliary device is provided with a broach, the broach is vibrated by the ultrasonic auxiliary device, and the internal gear broaching is performed on the internal gear workpiece by the vibrating broach. The application can improve the machining precision of the internal gear.

Description

Technical Field

[0001] This application relates to the field of machining technology, and in particular to a horizontal ultrasonic broaching machine and a method for designing efficient broaching parameters. Background Technology

[0002] High-strength internal gears are key components in high-end equipment such as aero engines and gas turbines. They are made of materials with high strength and hardness, requiring high machining precision. Broaching can improve machining efficiency and accuracy. However, traditional machining processes for cutting high-hardness, high-strength materials result in high unit cutting heat, large fluctuations in heat amplitude, short tool life, and require further improvement in machining accuracy. Summary of the Invention

[0003] This application aims to propose a horizontal ultrasonic gear broaching machine and an efficient broaching parameter design method, which can improve the machining accuracy of internal gears.

[0004] In a first aspect, embodiments of this application provide a horizontal ultrasonic gear broaching machine tool, the horizontal ultrasonic gear broaching machine tool comprising:

[0005] A base, in which a stepper motor is fixedly installed;

[0006] A C-shaped cradle is installed inside the base. The rack of the C-shaped cradle is slidably connected to the gear of the stepper motor inside the base. The rack of the C-shaped cradle is driven to rotate by the gear of the stepper motor.

[0007] A workbench is installed on the C-shaped cradle. The workbench and the C-shaped cradle are connected by a first lead screw. The stepper motor drives the workbench to move horizontally on the C-shaped cradle.

[0008] A rotary table is fixedly provided with a turbine disk, which is used to fix the internal gear workpiece. The rotary table is mounted on the worktable and is driven to rotate on the worktable by the stepper motor. The turbine disk rotates with the rotary table.

[0009] An ultrasonic-assisted device is provided with a broach. The broach is made to vibrate by the ultrasonic-assisted device, and the vibrating broach is used to broach the internal gear workpiece.

[0010] Compared with the prior art, the first aspect of this application has the following beneficial effects:

[0011] The C-shaped cradle is driven to rotate by a stepper motor in the base, the worktable is driven to move horizontally on the C-shaped cradle, and the turntable is driven to rotate on the worktable by the stepper motor. The turbine disk used to fix the internal gear workpiece rotates with the turntable. Then, the broach is made to vibrate by an ultrasonic auxiliary device, and the internal gear workpiece is broached by the broach that generates the vibration. In this way, the machining accuracy of the internal gear can be improved by ultrasonic vibration-assisted broaching, and the unit cutting heat and fluctuation amplitude can be reduced, thereby increasing the tool life.

[0012] Secondly, this application also provides an efficient broaching parameter design method, applied in the aforementioned horizontal ultrasonic gear broaching machine tool, the efficient broaching parameter design method comprising:

[0013] Construct a function to calculate broaching parameters, wherein the broaching parameters include the limiting cutting speed and the ultrasonic vibration power;

[0014] A conventional cutting test was conducted to obtain the first cutting force corresponding to the conventional test.

[0015] An ultrasonic-assisted cutting test was conducted, the cutting speed was set, and the second cutting force during the ultrasonic-assisted cutting test was collected.

[0016] The approximation degree between the second cutting force and the first cutting force is calculated. If the approximation degree is within a preset range, the current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force are substituted into the function of the broaching parameters to calculate the broaching parameters. The approximation degree is used to indicate the multiple relationship between the second cutting force and the first cutting force.

[0017] Compared with the prior art, the second aspect of this application has the following beneficial effects:

[0018] This method constructs a function to calculate broaching parameters. Through conventional cutting tests and ultrasonic-assisted cutting tests, it obtains the first and second cutting forces. Then, it calculates the approximation between the second and first cutting forces. If the approximation is within a preset range, it substitutes the obtained current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and second cutting force into the broaching parameter function to calculate the broaching parameters. In this way, by considering the relationship between conventional cutting tests and ultrasonic-assisted cutting tests, accurate limiting cutting speeds and ultrasonic vibration power can be obtained. Accurate limiting cutting speeds and ultrasonic vibration power can improve the machining accuracy of internal gears and increase ultrasonic cutting efficiency.

[0019] In some implementations, the function for calculating the limiting cutting speed is constructed as follows:

[0020] f(h f ,f v ,h c b) = k1h f f v h c b

[0021] Among them, h f f represents the amplitude of ultrasonic vibration. v The frequency of ultrasonic vibration, h c denoted by , b represents the cutting depth, b represents the cutting width, and k1 represents the fitting coefficient.

[0022] In some implementations, the function for calculating ultrasonic vibration power is constructed as follows:

[0023] 0.25P = P1 + P2

[0024]

[0025]

[0026] Where P represents the ultrasonic vibration power, P1 represents the power required for the ultrasonic vibration amplitude transformer to stabilize its vibration, P2 represents the power required for the ultrasonic vibration amplitude transformer end to output vibration amplitude under cutting load, and h f f represents the amplitude of ultrasonic vibration. v ψ represents the ultrasonic vibration frequency. s F represents the force resistance of the ultrasonic system. v This represents the cutting force collected in the ultrasonic-assisted cutting test. This indicates the speed of ultrasonic vibration.

[0027] In some implementations, the ultrasonic vibration velocity is calculated as follows:

[0028]

[0029] in, The value represents the ultrasonic vibration velocity, t represents time, and h represents the time. f f represents the amplitude of ultrasonic vibration. v This indicates the frequency of ultrasonic vibration.

[0030] In some embodiments, after calculating the approximation between the second cutting force and the first cutting force, the efficient broaching parameter design method further includes:

[0031] If the degree of approximation is lower than the preset range, the cutting speed is increased until the degree of approximation is within the preset range;

[0032] The current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force are substituted into the function of the broaching parameters to calculate the broaching parameters.

[0033] In some embodiments, after calculating the approximation between the second cutting force and the first cutting force, the efficient broaching parameter design method further includes:

[0034] If the degree of approximation is higher than the preset range, the cutting speed is reduced; if, after reducing the cutting speed, the degree of approximation is lower than the preset range, the cutting speed is increased until the degree of approximation is within the preset range.

[0035] The current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force are substituted into the function of the broaching parameters to calculate the broaching parameters.

[0036] Thirdly, embodiments of this application also provide an efficient broaching parameter design system, the efficient broaching parameter design system comprising:

[0037] A function construction unit is used to construct a function for calculating broaching parameters, wherein the broaching parameters include the limiting cutting speed and the ultrasonic vibration power;

[0038] The conventional cutting test unit is used to conduct conventional cutting tests and obtain the first cutting force corresponding to the conventional test.

[0039] An ultrasonic-assisted cutting test unit is used to conduct ultrasonic-assisted cutting tests, set the cutting speed, and collect the second cutting force during the ultrasonic-assisted cutting test process.

[0040] The broaching parameter calculation unit is used to calculate the approximation degree between the second cutting force and the first cutting force. If the approximation degree is within a preset range, the current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force are substituted into the broaching parameter function to calculate the broaching parameters. The approximation degree is used to indicate the multiple relationship between the second cutting force and the first cutting force.

[0041] Fourthly, embodiments of this application also provide an electronic device, including at least one control processor and a memory for communicatively connecting to the at least one control processor; the memory stores instructions executable by the at least one control processor, the instructions being executed by the at least one control processor to enable the at least one control processor to perform an efficient broaching parameter design method as described above.

[0042] Fifthly, embodiments of this application also provide a computer-readable storage medium storing computer-executable instructions for causing a computer to execute an efficient broaching parameter design method as described above.

[0043] It is understood that the beneficial effects of the third to fifth aspects compared with the related technologies are the same as the beneficial effects of the second aspect compared with the related technologies. Please refer to the relevant description in the second aspect above, which will not be repeated here. Attached Figure Description

[0044] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0045] Figure 1 This is a structural schematic diagram of a horizontal ultrasonic gear broaching machine provided in this application;

[0046] Figure 2 This is a flowchart illustrating an efficient broaching parameter design method provided in this application;

[0047] Figure 3 This is a schematic diagram of the structure of an efficient broaching parameter design system provided in this application;

[0048] Labeling Explanation: 100, base; 200, pedestal; 300, C-shaped cradle; 400, worktable; 500, turntable; 600, ultrasonic auxiliary device; 601, broach. Detailed Implementation

[0049] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0050] In the description of this application, the use of terms such as "first," "second," etc., is for the purpose of distinguishing technical features only and should not be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated or the order of the technical features indicated.

[0051] In the description of this application, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0052] In the description of this application, it should be noted that, unless otherwise explicitly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0053] High-strength internal gears are key components in high-end equipment such as aero engines and gas turbines. They are made of materials with high strength and hardness, requiring high machining precision. Broaching can improve machining efficiency and accuracy. However, traditional machining processes for cutting high-hardness, high-strength materials result in high unit cutting heat, large fluctuations in heat amplitude, short tool life, and require further improvement in machining accuracy.

[0054] To address the aforementioned problems of high unit cutting heat, large fluctuation amplitude, short tool life, and low machining accuracy, this application proposes a horizontal ultrasonic broaching machine and an efficient broaching parameter design method.

[0055] Reference Figure 1 This application provides a horizontal ultrasonic gear broaching machine, which includes:

[0056] A stepper motor is fixedly installed inside the base 200;

[0057] A C-shaped cradle 300 is installed inside the base 200. The rack of the C-shaped cradle 300 is slidably connected to the gear of the stepper motor inside the base 200. The rack of the C-shaped cradle 300 is driven to rotate by the gear of the stepper motor.

[0058] The worktable 400 is installed on the C-shaped cradle 300. The worktable 400 and the C-shaped cradle 300 are connected by the first lead screw. The worktable 400 is driven by a stepper motor to move horizontally on the C-shaped cradle 300.

[0059] A turbine disk is fixedly installed on a turntable 500. The turbine disk is used to fix the internal gear workpiece. The turntable 500 is installed on the worktable 400 and is driven to rotate on the worktable 400 by a stepper motor. The turbine disk rotates with the turntable 500.

[0060] The ultrasonic-assisted device 600 is equipped with a broach 601. The broach 601 is made to vibrate by the ultrasonic-assisted device 600, and the vibrating broach 601 is used to broach the internal gear workpiece.

[0061] In this embodiment, the C-shaped cradle 300 is rotated by a stepper motor in the base 200, the worktable 400 is moved horizontally on the C-shaped cradle 300, and the turntable 500 is rotated on the worktable 400 by the stepper motor. The turbine disk used to fix the internal gear workpiece rotates with the turntable 500. Then, the broach 601 is vibrated by the ultrasonic auxiliary device 600, and the internal gear workpiece is broached by the vibrating broach 601. In this way, the machining accuracy of the internal gear can be improved by ultrasonic vibration-assisted broaching, and the cutting heat can be significantly improved by ultrasonic vibration assistance, thereby improving machining performance, reducing fluctuation amplitude, and increasing tool life.

[0062] The aforementioned C-shaped cradle 300 can be a C-shaped cradle used in a horizontal ultrasonic gear broaching machine for machining internal gears.

[0063] The aforementioned ultrasonic auxiliary device 600 can be a device for generating ultrasonic vibrations, and can be an ultrasonic auxiliary device in the prior art, which will not be specifically described in this embodiment.

[0064] The broach 601 mentioned above can be any cutting tool used for broaching internal gear workpieces.

[0065] To facilitate understanding by those skilled in the art, a set of preferred embodiments is provided below:

[0066] Reference Figure 1 , Figure 1 This is a structural diagram of a horizontal ultrasonic gear broaching machine. The machine includes: a base 100, a pedestal 200, a C-shaped cradle 300, a worktable 400, a rotary table 500, an ultrasonic auxiliary device 600, and a tool magazine 700. Specifically:

[0067] The base 100 is fixed on the foundation and is connected to the base 200, usually by multiple bolts.

[0068] The lower end of the base 200 is connected to the base 100. The inner side of the base 200 is a C-shaped surface, and the base 200 is slidably connected to the C-shaped cradle 300. The C-shaped cradle 300 is driven by a stepper motor fixed inside the base 200, which rotates a gear and then drives a rack mounted on the outer side of the C-shaped cradle 300 to move, thereby causing the C-shaped cradle 300 to rotate around the axis of the C-shaped arc surface on the outer side of the cradle, realizing the rotation of the A-axis. When the motor stops moving, the C-shaped cradle 300 is fixed in position by the gear connected to the motor by its rack.

[0069] A worktable 400 is installed on the C-shaped cradle 300. The worktable 400 is connected to and driven by two lead screws, enabling the worktable 400 to move in two horizontal directions on the upper surface of the C-shaped cradle 300.

[0070] The worktable 400 and the rotary table 500 are connected and driven to rotate by a stepper motor. The rotary table 500 is driven to rotate on the worktable 400 by the stepper motor.

[0071] The turbine disk workpiece is fixed on the rotary table 500, and the turbine disk rotates with the rotary table 500. Through the motion combination of the C-shaped cradle 300, the worktable 400 and the rotary table 500, the six-axis non-linkage motion of the horizontal ultrasonic gear broaching machine is realized.

[0072] The specially structured ultrasonic auxiliary device 600 is equipped with a puller 601, which is detachably connected to the ultrasonic auxiliary device 600.

[0073] Tool magazine 700 and related accessories are used to store and replace tools.

[0074] Reference Figure 2 This application also provides an efficient broaching parameter design method, applied to the above-mentioned horizontal ultrasonic gear broaching machine. This efficient broaching parameter design method includes the following steps:

[0075] Step S100: Construct a function to calculate broaching parameters, wherein the broaching parameters include the limiting cutting speed and the ultrasonic vibration power;

[0076] Step S200: Conduct a conventional cutting test to obtain the first cutting force corresponding to the conventional test.

[0077] Step S300: Conduct an ultrasonic-assisted cutting test, set the cutting speed, and collect the second cutting force during the ultrasonic-assisted cutting test.

[0078] Step S400: Calculate the approximation degree between the second cutting force and the first cutting force. If the approximation degree is within a preset range, substitute the current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and second cutting force into the broaching parameter function to calculate the broaching parameters. The approximation degree is used to indicate the multiple relationship between the second cutting force and the first cutting force.

[0079] In this embodiment, a function for calculating broaching parameters is constructed. Through conventional cutting tests and ultrasonic-assisted cutting tests, a first cutting force and a second cutting force are obtained. Then, the approximation degree between the second cutting force and the first cutting force is calculated. If the approximation degree is within a preset range, the obtained current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and second cutting force are substituted into the broaching parameter function to calculate the broaching parameters. Thus, by considering the relationship between conventional cutting tests and ultrasonic-assisted cutting tests, accurate limiting cutting speeds and ultrasonic vibration power can be obtained. Accurate limiting cutting speeds and ultrasonic vibration power can improve the machining accuracy of internal gears and increase ultrasonic cutting efficiency.

[0080] In some implementations, the function for calculating the limiting cutting speed is constructed as follows:

[0081] f(h f ,f v ,h c b) = k1h f f v h c b

[0082] Among them, h f f represents the amplitude of ultrasonic vibration. v The frequency of ultrasonic vibration, h c denoted by , b represents the cutting depth, b represents the cutting width, and k1 represents the fitting coefficient.

[0083] In some implementations, the function for calculating ultrasonic vibration power is constructed as follows:

[0084] 0.25P = P1 + P2

[0085]

[0086]

[0087] Where P represents the ultrasonic vibration power, P1 represents the power required for the ultrasonic vibration amplitude transformer to stabilize its vibration, P2 represents the power required for the ultrasonic vibration amplitude transformer end to output vibration amplitude under cutting load, and h f f represents the amplitude of ultrasonic vibration. v ψ represents the ultrasonic vibration frequency. s F represents the force resistance of the ultrasonic system. v This represents the cutting force collected in the ultrasonic-assisted cutting test. This indicates the speed of ultrasonic vibration.

[0088] In some implementations, ultrasonic vibration velocity is calculated as follows:

[0089]

[0090] in, The value represents the ultrasonic vibration velocity, t represents time, and h represents the time. f f represents the amplitude of ultrasonic vibration. v This indicates the frequency of ultrasonic vibration.

[0091] In some implementations, after calculating the approximation between the second cutting force and the first cutting force, the efficient broaching parameter design method further includes:

[0092] If the approximation is lower than the preset range, increase the cutting speed until the approximation is within the preset range;

[0093] The current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and second cutting force are substituted into the broaching parameter function to calculate the broaching parameters.

[0094] In this embodiment, when the approximation degree is lower than the preset range, the cutting speed is increased to bring the approximation degree within the preset range, thereby ensuring the accuracy of the calculated broaching parameters.

[0095] In some implementations, after calculating the approximation between the second cutting force and the first cutting force, the efficient broaching parameter design method further includes:

[0096] If the approximation is higher than the preset range, reduce the cutting speed; if the approximation is lower than the preset range after reducing the cutting speed, increase the cutting speed until the approximation is within the preset range.

[0097] The current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and second cutting force are substituted into the broaching parameter function to calculate the broaching parameters.

[0098] In this embodiment, when the approximation degree is higher than the preset range, the cutting speed is reduced to bring the approximation degree within the preset range. However, if the reduction in cutting speed is too large, causing the approximation degree to be lower than the preset range, the cutting speed is increased to bring the approximation degree within the preset range, thereby ensuring the accuracy of the calculated broaching parameters.

[0099] To facilitate understanding by those skilled in the art, a set of preferred embodiments is provided below:

[0100] Based on the existing mature structure of horizontal broaching machines, the structural design of a horizontal ultrasonic gear broaching machine is carried out, and an ultrasonic device matching the target process parameters is constructed.

[0101] Let the current maximum speed limit of a high-speed broaching machine be vm. To ensure that ultrasonic assistance can significantly improve machining performance, and considering that the limiting cutting speed for ultrasonic assistance effectiveness is closely related to parameters such as the tool and workpiece material, a right-angle ultrasonic assistance test was conducted to obtain the limiting speed for ultrasonic-assisted cutting effectiveness. The detailed process is as follows:

[0102] 1) The tool angle and material used for conducting right-angle cutting tests are the same as those used for actual broaching.

[0103] 2) Since ultrasonic vibration amplitude and frequency significantly affect cutting performance, and cutting width and depth of cut in the cutting process parameters significantly affect cutting force, and cutting force has a significant inhibitory effect on ultrasonic vibration amplitude, it is necessary to construct a model that considers the influence of cutting force on cutting amplitude, and thus on the effective limiting cutting speed, as follows:

[0104] v m =f(h f ,f v ,h c b)

[0105] Since the horizontal ultrasonic gear broaching machine is a specialized machine tool, its cutting width and depth of cut during broaching are determined by the tool structure. Therefore, when conducting cutting tests, the cutting width and depth of cut are consistent with the cutting width and tooth rise of the broaching tool, which can significantly improve the effective limiting cutting speed of ultrasonic-assisted cutting. That is, the above formula can be simplified to:

[0106] v m =f(h f ,f v ,h c b)

[0107] Among them, h c b represents the depth of cut, h represents the width of cut, and b represents the cutting width. c b is known, h f f represents the amplitude of ultrasonic vibration. v This indicates the frequency of ultrasonic vibration.

[0108] Let the function model be:

[0109] f(h f ,f v ,h c b) = k1h f f v h c b(1)

[0110] Where k1 represents the coefficient that needs to be fitted through cutting tests.

[0111] The first set of cutting tests was conducted; this was a conventional cutting test, and the cutting force measured was F.c ,

[0112] The second set of cutting tests was conducted, specifically ultrasonic-assisted cutting tests. The rated power (i.e., ultrasonic vibration power) of the ultrasonic power supply was P, with an output percentage of 25%. The ultrasonic vibration amplitude was measured as h using a Doppler laser vibrometer. f Ultrasonic vibration is a strong vibration, therefore it is consistent with the power of the ultrasonic power supply, and the power supply frequency is 20000Hz.

[0113] The rated output power of the ultrasonic power supply needs to meet the power P1 required for stable vibration of the ultrasonic vibration amplitude transformer and the power P2 required for the ultrasonic vibration amplitude transformer end to output vibration amplitude under cutting load. The calculation process to meet these conditions is expressed as follows:

[0114] 0.25P = P1 + P2

[0115]

[0116]

[0117]

[0118] Where P represents the ultrasonic vibration power, P1 represents the power required for the ultrasonic vibration amplitude transformer to stabilize its vibration, P2 represents the power required for the ultrasonic vibration amplitude transformer end to output vibration amplitude under cutting load, and h f f represents the amplitude of ultrasonic vibration. v This represents the ultrasonic vibration frequency, typically 20000Hz, ψ s The force resistance of the ultrasonic system, equivalent to its modal damping, is obtained through finite element modal analysis, F. v This represents the cutting force collected in the ultrasonic-assisted cutting test, specifically the cutting force in the direction of the cutting velocity, which can be measured in real time using a force gauge. The ultrasonic vibration velocity is the derivative of the ultrasonic vibration displacement with respect to time, where t represents time.

[0119] The ultrasonic vibration displacement change of the ultrasonic vibration amplitude transformer is obtained by measuring with a Doppler laser vibrometer, as shown in the following formula:

[0120] ζ=h f sin(2πf v t)

[0121] Where ζ represents the ultrasonic vibration displacement, which is the displacement that changes over time.

[0122] When calculating the initial power, based on the existing process parameters, the limiting parameters are initially estimated as follows: ultrasonic vibration amplitude is 5 micrometers, ultrasonic vibration frequency is 20000 Hz (Hertz), and cutting force load is 10 kN.

[0123] The above preliminary estimation of limiting parameters based on existing process parameters can be conventional limiting parameters in the prior art. This embodiment does not provide a specific description of the preliminary estimation of limiting parameters.

[0124] In conventional cutting processes, the cutting speed has a relatively small impact on the cutting force. However, in ultrasonic-assisted cutting, the cutting speed significantly affects the ultrasonic cutting process, the cutting mechanism, and the cutting force. Considering the differences between actual cutting and broaching processes, to ensure that the critical cutting speed can be effectively used in broaching, the cutting speed is set to 1.2 times the commonly used broaching speed v1. The commonly used broaching speed is 10 m / min. Therefore, the experimental cutting speed is set to... The speed is 12 m / min.

[0125] Step A) If the cutting force F collected in the ultrasonic-assisted cutting test v Approximately the conventional cutting force F c 0.8 times, or 0.75F c ≤F v ≤0.85F c Then, by substituting the current cutting width, cutting depth, ultrasonic vibration amplitude, ultrasonic vibration frequency and cutting speed into formula (1), we can obtain the coefficient k1.

[0126] The ultrasonic vibration frequency mentioned above can be obtained by measurement or set to 20000Hz, because the ultrasonic system is excited by a piezoelectric actuator, and the power supply frequency driving the piezoelectric actuator is 20000Hz.

[0127] Step B) If the cutting force F collected in the ultrasonic-assisted cutting test v Lower than the conventional cutting force F c 0.8 times, that is, F v <0.75F c Since the effect of cutting speed on cutting force is nonlinear, the optimal value is obtained through continuous adjustment and measurement. Increasing the cutting speed to 1.1 times the original cutting speed, i.e., the cutting speed...

[0128] Step B1) If the cutting force F v Approximately conventional cutting force F c If 80% of the value is obtained, such as in step A), then the current cutting width, cutting depth, ultrasonic vibration amplitude, ultrasonic vibration frequency and cutting speed are substituted into formula (1) to obtain the coefficient k1.

[0129] Step B2) If the cutting force F collected in the ultrasonic-assisted cutting test v Lower than the conventional cutting force F c If the cutting speed is 0.8 times the speed of the cutting machine, then continue to increase the cutting speed v2 and repeat step B).

[0130] Step C) If the cutting force F collected in the ultrasonic-assisted cutting test v Higher than conventional cutting force F c 0.8 times, that is, F v >0.85F c If the cutting speed is reduced to 0.9 times the original cutting speed, i.e., cutting speed v3 = 0.9v2, an ultrasonic-assisted cutting test is conducted. If the cutting force F collected in the ultrasonic-assisted cutting test... v Approximately the conventional cutting force F c 0.8 times, and obtain the coefficient k1 by solving according to step A); if the cutting force F collected by the ultrasonic assisted cutting test v Lower than the conventional cutting force F c The cutting force F collected by the ultrasonic-assisted cutting test is 0.8 times that of the sample, and processed according to step B); v Higher than conventional cutting force F c If the cutting force is 0.8 times that of the ultrasonic-assisted cutting test, proceed according to step C) until the cutting force F collected in the ultrasonic-assisted cutting test is obtained. v Approximately the conventional cutting force F c Substituting 0.8 times into equation (1) yields the coefficient k1. After obtaining the coefficient k1, the limiting broaching speed is then obtained.

[0131] By following the steps A) to C) above, accurate limiting cutting speed and ultrasonic vibration power for broaching can be obtained. Compared with the existing ultrasonic cutting parameter optimization process, the accuracy is significantly improved and the ultrasonic cutting efficiency is greatly improved.

[0132] When broaching an internal gear, the internal gear is fixed on a turntable. The broach of the ultrasonic-assisted device passes through the internal gear. Under the push of the slider in the horizontal ultrasonic gear broaching machine, the broach moves from left to right, broaching the gear. After machining, the slider pushes the broach to the left, the broach exits the internal gear, the workpiece is removed, and the broaching of the internal gear is completed. Repeat the above steps to complete the machining.

[0133] Reference Figure 3 This application also provides an efficient broaching parameter design system, which includes a function construction unit 310, a conventional cutting test unit 320, an ultrasonic-assisted cutting test unit 330, and a broaching parameter calculation unit 340, wherein:

[0134] Function construction unit 310 is used to construct a function for calculating broaching parameters, wherein the broaching parameters include the limiting cutting speed and ultrasonic vibration power;

[0135] The conventional cutting test unit 320 is used to conduct conventional cutting tests and obtain the first cutting force corresponding to the conventional test.

[0136] The ultrasonic-assisted cutting test unit 330 is used to conduct ultrasonic-assisted cutting tests, set the cutting speed, and collect the second cutting force during the ultrasonic-assisted cutting test process.

[0137] The broaching parameter calculation unit 340 is used to calculate the approximation degree between the second cutting force and the first cutting force. If the approximation degree is within a preset range, the current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and second cutting force are substituted into the broaching parameter function to calculate the broaching parameters. The approximation degree is used to indicate the multiple relationship between the second cutting force and the first cutting force.

[0138] It should be noted that since the efficient broaching parameter design system in this embodiment is based on the same inventive concept as the efficient broaching parameter design method described above, the corresponding content in the method embodiment is also applicable to this system embodiment, and will not be described in detail here.

[0139] This invention also provides an electronic device, including: at least one control processor and a memory for communicatively connecting to the at least one control processor.

[0140] Memory, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs and non-transitory computer-executable programs. Furthermore, memory may include high-speed random access memory, and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, memory may optionally include memory remotely located relative to the processor, and these remote memories can be connected to the processor via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0141] The non-transient software program and instructions required to implement the efficient broaching parameter design method of the above embodiments are stored in memory. When executed by a processor, the efficient broaching parameter design method of the above embodiments is executed, for example, the method described above is executed. Figure 2 Method steps S100 to S400.

[0142] The system embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0143] This invention also provides a computer-readable storage medium storing computer-executable instructions. These instructions, when executed by one or more control processors, cause the processors to perform an efficient broaching parameter design method as described in the above-described method embodiments. For example, they can execute the methods described above. Figure 2 The functions of steps S100 to S400 in the method.

[0144] It will be understood by those skilled in the art that all or some of the steps and systems in the methods disclosed above can be implemented as software, firmware, hardware, and suitable combinations thereof. Some or all of the physical components can be implemented as software executed by a processor, such as a central processing unit, digital signal processor, or microprocessor, or as hardware, or as an integrated circuit, such as an application-specific integrated circuit. Such software can be distributed on a computer-readable medium, which can include computer storage media (or non-transitory media) and communication media (or transient media). As is known to those skilled in the art, the term computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information (such as computer-readable instructions, data structures, program modules, or other data). Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disc (DVD) or other optical disc storage, magnetic cartridges, magnetic tape, disk storage or other magnetic storage devices, or any other medium that can be used to store desired information and is accessible to a computer. Furthermore, as is known to those skilled in the art, communication media typically contain computer-readable instructions, data structures, program modules, or other data in modulated data signals such as carrier waves or other transmission mechanisms, and may include any information delivery medium.

[0145] The above is a detailed description of the preferred embodiments of this application. However, the embodiments of this application are not limited to the above-described implementation methods. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the embodiments of this application. All such equivalent modifications or substitutions are included within the scope defined by the claims of the embodiments of this application.

Claims

1. A method for designing efficient broaching parameters, characterized in that, This technology is applied in horizontal ultrasonic gear broaching machines, which include: A base, in which a stepper motor is fixedly installed; a C-shaped cradle, disposed within the base, wherein the rack of the C-shaped cradle meshes with the gear of the stepper motor within the base, and the gear of the stepper motor drives the rack of the C-shaped cradle to rotate; a worktable, mounted on the C-shaped cradle, connected to the C-shaped cradle by a first lead screw, the worktable being driven by the stepper motor to move horizontally on the C-shaped cradle; a turntable, on which a turbine disk is fixedly installed, the turbine disk being used to fix the internal gear workpiece, the turntable being mounted on the worktable and driven by the stepper motor to rotate on the worktable, the turbine disk rotating with the turntable; an ultrasonic auxiliary device, comprising a broach, wherein the ultrasonic auxiliary device causes the broach to vibrate, and the vibrating broach performs internal gear broaching on the internal gear workpiece; The efficient broaching parameter design method includes: Construct a function to calculate broaching parameters, wherein the broaching parameters include the limiting cutting speed and the ultrasonic vibration power, including: in, Indicates the amplitude of ultrasonic vibration. Indicates the ultrasonic vibration frequency. Indicates the depth of cut. Indicates the cutting width. Represents the fitting coefficient; in, Indicates ultrasonic vibration power. This represents the power required for stable vibration of an ultrasonic vibration amplitude transformer. This represents the power required at the end of the ultrasonic vibration amplitude transformer to output the vibration amplitude under cutting load. Indicates the amplitude of ultrasonic vibration. Indicates the ultrasonic vibration frequency. Indicates the force resistance of the ultrasonic system. This represents the cutting force collected in the ultrasonic-assisted cutting test. Indicates ultrasonic vibration velocity; in, Indicates time, Indicates the amplitude of ultrasonic vibration. Indicates the ultrasonic vibration frequency; A conventional cutting test was conducted to obtain the first cutting force corresponding to the conventional test. An ultrasonic-assisted cutting test was conducted, the cutting speed was set, and the second cutting force during the ultrasonic-assisted cutting test was collected. Calculate the approximation degree between the second cutting force and the first cutting force. If the approximation degree is within a preset range, then substitute the obtained current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force into the broaching parameter function to calculate the broaching parameters. The approximation degree is used to indicate the multiple relationship between the second cutting force and the first cutting force, including: If the degree of approximation is lower than the preset range, the cutting speed is increased until the degree of approximation is within the preset range; The current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force are substituted into the function of the broaching parameters to calculate the broaching parameters; If the degree of approximation is higher than the preset range, the cutting speed is reduced; if, after reducing the cutting speed, the degree of approximation is lower than the preset range, the cutting speed is increased until the degree of approximation is within the preset range. The current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force are substituted into the function of the broaching parameters to calculate the broaching parameters.

2. A high-efficiency broaching parameter design system, characterized in that, The efficient broaching parameter design system, using the efficient broaching parameter design method of claim 1, comprises: A function construction unit is used to construct a function for calculating broaching parameters, wherein the broaching parameters include the limiting cutting speed and the ultrasonic vibration power; The conventional cutting test unit is used to perform conventional cutting tests and obtain the first cutting force corresponding to the conventional test. An ultrasonic-assisted cutting test unit is used to conduct ultrasonic-assisted cutting tests, set the cutting speed, and collect the second cutting force during the ultrasonic-assisted cutting test process. The broaching parameter calculation unit is used to calculate the approximation degree between the second cutting force and the first cutting force. If the approximation degree is within a preset range, the current cutting width, current cutting depth, current ultrasonic vibration amplitude, current ultrasonic vibration frequency, current cutting speed, and the second cutting force are substituted into the broaching parameter function to calculate the broaching parameters. The approximation degree is used to indicate the multiple relationship between the second cutting force and the first cutting force.

3. An electronic device, characterized in that, It includes at least one control processor and a memory for communicatively connecting to the at least one control processor; the memory stores instructions executable by the at least one control processor, which, when executed by the at least one control processor, enable the at least one control processor to perform the efficient broaching parameter design method as described in claim 1.

4. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer-executable instructions for causing a computer to perform the efficient broaching parameter design method as described in claim 1.

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